KAIZEN / POKA YOKE

Improvement Kaizen – 3’S

Company: Allena Auto Ind.Pvt Ltd. Deptt.: Prod Result: 3’S Improvement Month Jan.17

Subject:-:-Unwanted material removing Cleaning it. Process: Production

Productivity
Before After
Quality
√
Cost

Delivery

Safety
Morale

COMMENTS :. Unwanted items laying COMMENTS:. All unwanted material 5S √

on the back side of the Prod area removed & sold out. Others
Why-Why Analysis Horizontal Deployment Cost saving/year
Because 5’Zone not defined These activities doing in all areas. Date of Imple.

Benefits: 1. 3’ S Improved (Cleaning) Suggested by

2. Unwanted material scrapped Approved by
3. Cost saving
4. It can cause health problem. Waste materials should be dispose
immediately.
 Improvement Kaizen – 3’S
Company: Allena Auto Ind.Pvt Ltd. Deptt.: Result: Safety Improvement Month Feb.17
Assembly
Subject:-:- Leakage testing of part Process: Production

Productivity
Before After
Quality
√
Cost

Delivery

Safety
Morale

COMMENTS :. AIR PIPE LINE COVERING COMMENTS:. WORKING AREA SAVE & REDUCE 5S √
WORKING AREA & THERE IS CHANCE OF ACCIDENT CHANCE OF ACCIDENT AFTER DESIGN CHANGE OF AIR
Others
DUE TO EXCESS LENGTH OF PIPE PIPE LINE

Horizontal Deployment Cost saving/year

These activities doing in all areas. Date of Imple.

BENEFITS:- 1.Increased safety of workers and reduces the chances of accident. Suggested by
2.pressure system modified Approved by
 Improvement Kaizen on 5’S
Company: Tharaj Castings Pvt. Ltd Deptt. :- Result :- Quality,5’S , Packing Month Dec.16
Quality Deptt efficiency Improved.

Subject:-: Providing tables for packing A/Clutch Process :- Quality packing area
23266-68K02

Before After Productivity

Quality √
Cost

Delivery √
Safety

Morale

COMMENTS :- All workers in Arm Clutch COMMENTS:- Table provided to the workers for 5S √
shop were sitting on the floor for packing packing
materials. Others

Why-Why Analysis Horizontal Deployment Cost saving/Year

There was no working table available. We have provided the working / inspection tables
Date of
where needed. 30/12/2016
Implementation

BENEFITS:- 1. Packing Increased 10 % Suggested by Mr.Open

2. 5’S Maintained
3. Time Saving and minimizing fatigue. Approved by
4
 Improvement Kaizen – 3’S
Company: Allena Auto Ind.Pvt Ltd. Deptt.: Prod Result: 3’S Improvement Month Jan.17

Subject:-:- Scrap capturing Process: Behind tool room Production

Productivity
Before After
Quality
√
Cost

Delivery

Safety
Morale

COMMENTS :. It can cause health COMMENTS:. Mixed scrap area 5S √

problem. Litters should be dispose on improved. Different bins provided for Others
daily basis. different scraps.
Why-Why Analysis Horizontal Deployment Cost saving/year
Because 5’Zone not defined These activities doing in all areas. Date of Imple.

Benefits: 1. 3’ S Improved (Cleaning) Suggested by

2. Unwanted material scrapped Approved by
3. Different bins for different scraps.
 Improvement Kaizen on Safety
Company: Allena Auto Ind. Pvt. Ltd Deptt. :- Result :- Safety Month of Report OCT .16
Prod. Improvement
Subject:-: Passage was not clear in Prod deptt. Process :- Passage.

Before After Productivity

Quality

Cost

Delivery

Safety √
Morale

COMMENTS :- Passage was not clear in case of COMMENTS: - Now clear passage given with 5S √
emergency. display of ‘’Emergency exits’’.
Others

Why-Why Analysis Horizontal Deployment Cost saving/Year

Due to lack of awareness. These activities doing in all other areas.
Date of
Implementation

•BENEFITS:- 1. Increased safety of employess and reduces the chances of accident. Suggested by

Material movement improved.(3) time saving Approved by 6

 Improvement Kaizen on Safety
Company: Allena Auto Ind. Pvt. Ltd Deptt. Powder Result :- Month of Report NOV .16
coating

Subject:-: Process :-

Before After Productivity

Quality

Cost

Delivery

Safety √
Morale

COMMENTS :- FUME PROBLEM WHEN OPEN COMMENTS: - PROVIDE FUME SUCTION DUCT 5S √
THE OVEN DOOR
Others

Why-Why Analysis Horizontal Deployment Cost saving/Year

No system for pollution & fume duct
Date of
Implementation

BENEFITS :- 1. Benefit of health of workers. Suggested by

2. Atmosphere pollution controlled
Approved by
7
 Improvement Kaizen on Safety
Company: Allena Auto Ind. Pvt. Ltd Deptt. :- Prod. Result :- Safety Improvement Month of Report Nov.16

Subject:-: Process :- 11641-86J00 MILLING

Before After Productivity

Quality

Cost

Delivery

Safety √
Morale

COMMENTS :- Chips were spreading out COMMENTS: - Now chip Guards provided 5S √
directly on floor. on machine.
Others

Why-Why Analysis Horizontal Deployment Cost saving/Year

Date of
These activities doing in all areas. Implementation

BENEFITS :- (1) 3’S Maintained. Suggested by

(2) Increased safety of workers and reduces the chances of accident
Approved by 8
 Improvement Poka Yoke
Allena Auto phase VII-C116 Mohali
Deptt: Prod Month: Apr.17
Problem. :- Block detect Dim. As Cast
Part Name :- Bkt. 1155068KOO
10±0.50 Observed
Before After

CONTAIMENT(Initiate Containment Works Sheet ): (Final Operation ) Before dimension not

checking in the receiving gauge after it dimensional proper checking on Receiver Gauge
 Improvement Kaizen on Safety
Company: Allena Auto Ind. Pvt. Ltd Deptt. :- Result :- Month of Report May .16
Prod.

Subject:-: Process :-

Before After Productivity

Quality

Cost

Delivery

Safety √
Morale

COMMENTS :- COMMENTS: - 5S √
Others

Why-Why Analysis Horizontal Deployment Cost saving/Year

Date of
Implementation

BENEFITS:- Suggested by

Approved by 10
 Improvement Kaizen on Safety
Company: Allena Auto Ind. Pvt. Ltd Deptt. :- Result :- Month of Report May .16
Prod.

Subject:-: Process :-

Before After Productivity

Quality

Cost

Delivery

Safety √
Morale

COMMENTS :- COMMENTS: - 5S √
Others

Why-Why Analysis Horizontal Deployment Cost saving/Year

Date of
Implementation

BENEFITS:- Suggested by

Approved by 11